Seat assembly with full seatback airbag

ABSTRACT

A seatback carrier module includes first and second side portions spaced-apart from one another and interconnected by an upper portion. A cradle portion is disposed along the first and second side portions and the upper portion of the seatback carrier module. The cradle portion includes inner and outer edges with a rearwardly extending body portion. A mounting portion is disposed along a portion of the inner edge of the cradle portion. The mounting portion includes inner and outer edges with a body portion disposed therebetween. The mounting portion further includes a rearwardly extending sidewall disposed along the inner edge of the mounting portion. An airbag assembly is received within the cradle portion and has an inverted U-shaped configuration to substantially surround the outer perimeter of the seatback frame. The airbag assembly is an elongate member defining an overhead airbag assembly.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a Continuation of U.S. patent applicationSer. No. 16/370,519 entitled “SEAT ASSEMBLY WITH FULL SEATBACK AIRBAG,”filed Mar. 29, 2019, which is incorporated herein by reference in itsentirety.

FIELD OF THE INVENTION

The present invention generally relates to a seat assembly, and moreparticularly, to a seat assembly having an integrated seatback carriersupporting an airbag system for deploying a full seat airbag.

BACKGROUND OF THE INVENTION

With the growing focus on autonomous or self-driving vehicles, new andflexible interior experiences are sought. With specific regard to seatassemblies, enhancements in occupant protection may be desired. This isparticularly the case in seating assemblies for autonomous vehicleswhich may be operable between various configurations, such as forwardand rearward facing orientations. The present concept provides anoverhead airbag system for a seatback that packages within a thinnerprofile for a seat design and provides traditional restraint needs in anunconventional way.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, a seatback carriermodule includes first and second side portions spaced-apart from oneanother and interconnected by an upper portion. A cradle portion isdisposed along the first and second side portions and the upper portionof the seatback carrier module. The cradle portion includes inner andouter edges with a rearwardly extending body portion. A mounting portionis disposed along a portion of the inner edge of the cradle portion. Themounting portion includes inner and outer edges with a body portiondisposed therebetween. The mounting portion further includes arearwardly extending sidewall disposed along the inner edge of themounting portion. An airbag assembly is received within the cradleportion.

According to another aspect of the present invention, a seatback carriermodule includes a mounting portion having inner and outer edges with abody portion disposed therebetween. The mounting portion furtherincludes a rearwardly extending sidewall disposed along the inner edgeof the mounting portion. A cradle portion is disposed along andsurrounds the outer edge of the mounting portion. The cradle portionincludes an outwardly opening raceway having first and second ends withan upwardly curved body portion disposed between the first and secondends. An airbag assembly is received within the outwardly openingraceway of the cradle portion for outward deployment therefrom.

According to yet another aspect of the present invention, a seatbackassembly includes a seatback frame having first and second side membersdefining a back support portion of the seatback frame. An upper framemember interconnects the first and second side members of the seatbackframe to define a headrest support portion of the seatback frame. Theupper frame member extends upwardly from the back support portion of theseatback frame. The seatback frame includes an outer perimeter disposedaround the first and second side members and the upper frame member. Aseatback carrier module is operably coupled to the seatback frame andincludes a cradle portion outwardly extending from the outer perimeterof the seatback frame. An airbag assembly is supported by the seatbackcarrier module. The airbag assembly is disposed on opposed sides of theback support portion of the seatback frame and is further disposed overthe headrest support portion of the seatback frame.

These and other aspects, objects, and features of the present inventionwill be understood and appreciated by those skilled in the art uponstudying the following specification, claims, and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a front perspective view of a seat assembly disposed within avehicle interior;

FIG. 2 is a front perspective view of the seat assembly of FIG. 1 asremoved from the vehicle interior;

FIG. 3 is a front perspective view of a seatback frame;

FIG. 4A is a front perspective view of a seatback carrier module;

FIG. 4B is a rear perspective view of the seatback carrier module ofFIG. 4A;

FIG. 4C is a front elevation view of the seatback carrier module of FIG.4A;

FIG. 5A is a front perspective view of the seatback carrier module ofFIG. 4A with an airbag assembly and two inflator mechanisms explodedaway therefrom;

FIG. 5B is a rear perspective view of the seatback carrier module ofFIG. 5A with the airbag assembly and the two inflator mechanismsreceived on the seatback carrier module;

FIG. 5C is a front perspective view of the seatback carrier module ofFIG. 5B;

FIG. 5D is a rear elevation view of the seatback carrier module of FIG.5B;

FIG. 5E is a front elevation view of the seatback carrier module of FIG.5B;

FIG. 6 is an exploded view of a seatback assembly;

FIGS. 7A-7C are top perspective views of the seatback carrier module ofFIG. 5B being mounted to the seatback frame of FIG. 3;

FIG. 8 is a front perspective view of a seatback assembly showing zoomedin portions at locations 8A and 8B;

FIG. 9 is a cross-sectional view of the seatback assembly of FIG. 8taken at line IX;

FIG. 10 is a cross-sectional view of the seatback assembly of FIG. 8taken at line X;

FIG. 11A is a front perspective view of a passenger seated in the seatassembly of FIG. 2 with an overhead airbag shown in a deployed position;and

FIG. 11B is a rear perspective view of the seat assembly and passengerof FIG. 11A.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

For purposes of description herein, the terms “upper,” “lower,” “right,”“left,” “rear,” “front,” “vertical,” “horizontal,” and derivativesthereof shall relate to the seat assembly as oriented in FIG. 1.However, it is to be understood that the invention may assume variousalternative orientations, except where expressly specified to thecontrary. It is also to be understood that the specific devices andprocesses illustrated in the attached drawings, and described in thefollowing specification are simply exemplary embodiments of theinventive concepts defined in the appended claims. Hence, specificdimensions and other physical characteristics relating to theembodiments disclosed herein are not to be considered as limiting,unless the claims expressly state otherwise.

Referring now to FIG. 1, a seat assembly 10 is shown disposed within aninterior 12A of a vehicle 12. Specifically, the seat assembly 10 isdisposed within the vehicle interior 12A adjacent to an instrument panelor dashboard 13. In FIG. 1, the seat assembly 10 is positioned in adriver's side seating area. However, it is contemplated that the seatassembly 10, or various components and features thereof, can be disposedon other seat assemblies positioned in other areas of a vehicle interior12A, such as the passenger side seating area, a rear seating area, or athird row seating option for example. The seat assembly 10 is shown inFIG. 1 as being supported on a vehicle floor support surface 14 andgenerally includes a substantially horizontal seat portion 16 and asubstantially upright seatback assembly 18. It is contemplated that theseat assembly 10 may also be supported on a track system for providingfore and aft movement within the vehicle interior 12A. It iscontemplated that the seatback assembly 18 may be a pivoting memberconfigured for reclining movement relative to the seat portion 16. It isfurther contemplated that the seat assembly 10 may rotate within thevehicle interior between forward-facing and rearward-facingorientations. As such, it is contemplated that the vehicle 12 may be anautonomous or self-driving vehicle, in which a seat assembly havingforward-facing and rearward-facing capabilities may be disposed.

As shown in FIGS. 1 and 2, a headrest assembly 20 is disposed on anupper portion of the seatback assembly 18 and includes a forwardlyextending headrest bun 20A. The headrest assembly 20 and the seatbackassembly 18 may be integrated components or modular components coupledto one another. As further shown in FIG. 1, the various parts of theseat portion 16 and the seatback assembly 18 are covered with seatcovers 21, 22, respectively. With specific regard to the seat cover 22of the seatback assembly 18, the seat cover 22 is contemplated toinclude various support materials, such as cloth and foam materialspackaged as an exterior comfort carrier module, that are used to covervarious frame materials supporting the seat assembly 10, as well ascover other components of the seat assembly 10, as further describedbelow.

As further shown in FIGS. 1 and 2, the seat assembly 10 includes arestraint system 24 having a seatbelt 26 with a belt guide 28 disposedat a shoulder height location along the seatback assembly 18. Therestraint system 24 of the present concept provides a seat occupant witha familiar restraining system using the seatbelt 26. However, therestraint system 24 is fully integrated into the seat assembly 10, suchthat the restraint system 24 does not require support or attachmentfeatures positioned within the vehicle interior 12A outside of the seatassembly 10, such as a standard B-column belt attachment location. Inthis way, the seat assembly 10 can alternate between forward-facing andrearward-facing configurations while still providing a consistentmechanism for passenger restraint in the integrated restraint system 24.

Referring now to FIG. 3, a seatback frame 30 is shown having a generallyinverted U-shaped configuration with a front side 30A and a rear side30B. The seatback frame 30 includes first and second side members 32, 34which are generally disposed in an upright orientation and spaced-apartfrom one another. Upper and lower cross members 36, 38 interconnect thefirst and second side members 32, 34 of the seatback frame 30 to definea generally centrally disposed window 40 therebetween. Within thecentrally disposed window 40, a suspension system 42 is disposedinterconnecting the first and second side members 32, 34. The first andsecond side members 32, 34 each comprise inner and outer frame members32A, 34A and 32B, 34B, respectively. The outer frame members 32B, 34Beach include inset portions 35 which inwardly extend laterally into thefirst and second side members 32, 34. The first and second side members32, 34 are contemplated to be mirror images of one another, such thatthe description of one side member also describes the other side memberin a mirrored configuration. Together, the first and second side members32, 34 define a back support portion 52 of the seatback frame 30.

As further shown in FIG. 3, an upper frame member 44 includes first andsecond side portions 46, 48 that interconnect with the first and secondside members 32, 34 of the seatback frame 30. Specifically, the firstand second side portions 46, 48 of the upper frame member 44 includeopposing ends 46A, 48A, respectively, which interconnect with upperportions of the first and second side members 32, 34 of the seatbackframe 30. The upper frame member 44 further includes an upper portion 50which interconnects the first and second side portions 46, 48 to definea headrest support portion 54 of the seatback frame 30. Thus, the firstand second side portions 46, 48 upwardly extend from the first andsecond side members 32, 34, of the seatback frame 30, and theninterconnect at upper portion 50 to generally define an overall invertedU-shaped configuration for the upper frame member 44. It is contemplatedthat the upper frame member 44 may be a unitary member interconnectingthe upper portions of the first and second side members 32, 34 of theseatback frame 30.

As further shown in FIG. 3, the headrest support portion 54 of theseatback frame 30 is disposed above the back support portion 52 of theseatback frame 30. Collectively, the first and second side members 32,34 and the upper frame member 44 cooperate to define an outer perimeter56 of the seatback frame 30. The outer perimeter 56 of the seatbackframe 30 extends around the first side member 32, around and over theupper frame member 44, and around the second side member 34 in agenerally inverted U-shaped configuration. Further, the seatback frame30 also includes an inner edge 58 which is defined by inner portions ofthe first and second side members 32, 34 and the upper frame member 44.As used herein, the term “inverted U-shaped configuration” is used todescribe a structural configuration in which two parallel orsubstantially parallel side members are interconnected at upper portionsthereof by an interconnecting member. The interconnecting member can bea straight member or an upwardly curved member (or portion of a unitarymember) that interconnects the side members. A component of the presentdisclosure described herein as having an inverted U-shaped configurationor a generally/substantially inverted U-shaped configuration may becomprised of multiple components to define an overall inverted U-shapedconfiguration, or may be a unitary monolithic part disposed in aninverted U-shaped configuration.

With further reference to FIG. 3, the seatback frame 30 includes aseatbelt retainer 60 having a mounting bracket 62 which is coupled tothe first side member 32 of the seatback frame 30 in the embodimentshown in FIG. 3. Specifically, the mounting bracket 62 is coupled to theouter frame member 32B of the first side member 32 at a mounting portion63 of the mounting bracket 62. The mounting bracket 62 further includesa plate portion 64 which outwardly extends from the mounting portion 63,such that, in an overall sense, the mounting bracket 62 outwardlyextends from the outer perimeter 56 of the seatback frame 30 at thefirst side member 32 thereof. The plate portion 64 of the mountingbracket 62 supports a retaining bar 66 thereon. The retaining bar 66 isshown in FIG. 3 in the form of a bar or tube that is outwardly extendingin a forward manner from a front side 64A of the plate portion 64 of themounting bracket 62. The retaining bar 66 includes first and second ends66A, 66B which are coupled to the plate portion 64 of the mountingbracket 62, such that a portion of the retaining bar 66 is spaced-apartfrom the plate portion 64 of the mounting bracket 62 for receiving aseatbelt and guiding the same therethrough and around the retaining bar66. In use, the seatbelt retainer 60 is configured to route a seatbeltof a seatbelt mechanism around a seat occupant, in a manner shown withrespect to the seatbelt 26 illustrated in FIG. 1. In the embodiment ofFIG. 3, the seatbelt retainer 60 is shown disposed on the first sidemember 32 of the seatback frame 30, however, it is also contemplatedthat the seatbelt retainer 60 may be disposed on the second side member34 of the seatback frame 30 to provide a seat assembly configured muchlike the seat assembly 10 shown in FIGS. 1 and 2. As such, it iscontemplated that the seatback frame 30 shown in FIG. 3 may be used as apassenger side seat assembly to provide for a crossing seatbeltconfiguration similar to a standard seatbelt configuration found in acar having non-rotating seat assemblies.

As further shown in FIG. 3, a mounting plate 70 is coupled to the uppercross member 36 of the seatback frame 30, and is further coupled to theupper frame member 44. The mounting plate 70 is provided add structuralsupport to the seatback frame 30 and to support components of the seatassembly 10, such as a seatbelt retractor mechanism 74. Another mountingplate 72 is shown disposed above mounting plate 70 on the upper framemember 44 between the first and second side portions 46, 48 thereof. Inthe embodiment shown in FIG. 3, the mounting plate 72 includes aretaining bar 76 mounted thereto which may be used to guide a seatbeltthrough the seat assembly 10, such as seatbelt 26 shown in FIGS. 1 and2.

Referring now to FIG. 4A, a seatback carrier module 90 is shown having agenerally inverted U-shaped configuration. The seatback carrier module90 includes a front side 90A and rear side 90B. The seatback carriermodule 90 includes first and second side members 92, 94 which aregenerally disposed in an upright orientation and spaced-apart from oneanother. The seatback carrier module 90 further includes an upper crossmember 96 that extends upwardly from and interconnects the first andsecond side members 92, 94 of the seatback carrier module 90 to define agenerally centrally disposed window 100 therebetween. In assembly, thecentrally disposed window 40 of the seatback frame 30 is configured toalign with the centrally disposed window 100 defined by the seatbackcarrier module 90. As further described below, the first and second sidemembers 92, 94 of the seatback carrier module 90 are disposed adjacentto the back support portion 52 of the seatback frame 30 in assembly.

It is contemplated that the seatback carrier module 90 is a unitarymember, wherein the upper cross member 96 and the first and second sidemembers 92, 94 of the seatback carrier module 90 are formed as amonolithic carrier member. It is further contemplated that the seatbackcarrier module 90 may be comprised of a polymeric material formed in asuitable injection molding process.

As further shown in FIG. 4A, the seatback carrier module 90 includes acradle portion 102 and a mounting portion 104. The cradle portion 102includes an inner edge 106 and an outer edge 108 with a rearwardlyextending body portion 110 disposed therebetween. It is contemplatedthat the rearwardly extending body portion 110 may be a curvedrearwardly extending body portion which defines a forwardly openingraceway 112 of the cradle portion 102. The raceway 112 of the cradleportion 102 may include a C-shaped cross-section for receiving andsupporting an airbag assembly, as further described below. As shown inFIG. 4A, the cradle portion 102 of the seatback carrier module 90 mayinclude a number of reinforcement struts 114 which span a width of theraceway 112 between the inner and outer edges 106, 108. In use, thereinforcement struts 114 provide structural stability to the cradleportion 102 of the seatback carrier module 90.

As further shown in FIG. 4A, the mounting portion 104 of the seatbackcarrier module 90 is disposed inboard of the cradle portion 102 of theseatback carrier module 90. Otherwise stated, the cradle portion 102 ofthe seatback carrier module 90 is disposed outboard of the mountingportion 104 of the seatback carrier module 90. In this way, the cradleportion 102 of the seatback carrier module 90 is outwardly disposedrelative to the mounting portion 104, such that the cradle portion 102of the seatback carrier module 90 outwardly surrounds the mountingportion 104 of the seatback carrier module 90. In the embodiment shownin FIG. 4A, the mounting portion 104 of the seatback carrier module 90includes an inner edge 116 and an outer edge 118 with a body portion 120disposed therebetween. It is contemplated that the outer edge 118 of themounting portion 104 may also define the inner edge 106 of the cradleportion 102 of the seatback carrier module 90. The mounting portion 104further includes an upper engagement member 122 having a rearwardlyextending sidewall 124 which extends rearwardly from the inner edge 116of the mounting portion 104. In use, the rearwardly extending sidewall124 is configured to cooperate with the body portion 120 of the mountingportion 104 to define an L-shaped cross-section which wraps around theinner edge 58 of the seatback frame 30 at the upper frame member 44 ofthe seatback frame 30, as further described below. Similarly, themounting portion 104 further includes lower engagement members 126, 128which are disposed on the first and second side members 92, 94respectively. As specifically shown in FIG. 4A, the lower engagementmembers 126, 128 are disposed adjacent to lowermost portions of thefirst and second side members 92, 94 and include rearwardly extendingsidewalls 126A, 128A, respectively. In use, the rearwardly extendingsidewalls 126A, 128A are configured to cooperate with the body portion120 to define an L-shaped cross-section which wraps around the inneredge 58 of the seatback frame 30 at lowermost portions of the first andsecond side members 32, 34 of the seatback frame 30, as furtherdescribed below. In this way, the mounting portion 104 of the seatbackcarrier module 90 is configured to securely couple the seatback carriermodule 90 to the seatback frame 30.

With further reference to FIG. 4A, the raceway 112 of the seatbackcarrier module 90 is configured to substantially span an entire lengthof the cradle portion 102 of the seatback carrier module 90. In thisway, the raceway 112 can support an airbag assembly which substantiallyfollows the contours of the seatback carrier module 90 for an entirelength or a portion of the length of the raceway 112, as furtherdescribed below. Thus, the raceway 112 is disposed along the cradleportion 102 of the seatback carrier module 90 between first and secondends 132, 134 of the seatback carrier module 90. As such, the raceway112 includes an inverted U-shaped configuration. As further shown inFIG. 4A, an access aperture 130 is disposed between the mounting portion104 and the cradle portion 102 of the seatback carrier module 90. Theaccess aperture 130 is positioned between the mounting portion 104 andthe cradle portion 102 of the seatback carrier module 90 to allow themounting bracket 62 of the seatbelt retainer 60 to extend therethroughwhen the seatback carrier module 90 is coupled to the seatback frame 30,as further described below.

Referring now to FIG. 4B, the seatback carrier module 90 is shown from arear perspective view, wherein lower access slots 136, 138 are showndisposed at lower portions of the first and second side members 92, 94of the seatback carrier module 90, respectively, to provide access tothe raceway 112 of the cradle portion 102. The lower access slots 136,138 are disposed along the rearwardly extending body portion 110 toprovide access to the raceway 112 for installing inflator mechanisms foran airbag assembly on the seatback carrier module 90, as well asproviding access for connecting features between the seatback carriermodule 90 and the seatback frame 30, as further described below. Thelower access slots 136, 138 are opposed access slots that open inwardlytowards the centrally disposed window 100 defined by the seatbackcarrier module 90.

In the embodiment shown in FIG. 4B, a plurality of reinforcement ribs115 are disposed around the cradle portion 102 on the rear side 90B ofthe seatback carrier module 90 to structurally reinforce the raceway 112of the cradle portion 102. Specifically, the reinforcement ribs 115 ofthe seatback carrier module 90 define rearwardly extending finsprojecting from the rear side 90B of the seatback carrier module 90 atthe body portion 110 of the cradle portion 102 of the seatback carriermodule 90. Similarly, a plurality of reinforcement ribs 117 are disposedaround the mounting portion 104 on the rear side 90B of the seatbackcarrier module 90 to structurally reinforce the mounting portion 104 ofthe seatback carrier module 90 at the intersection of the body portion120 of the mounting portion 104 and the rearwardly extending sidewalls124, 126A and 128A at the respective coupling portions 122, 126 and 128.

Referring now to FIG. 4C, the seatback carrier module 90 is shown from afront plan view, such that the entire raceway 112 of the cradle portion102 of the seatback carrier module 90 is visible. As shown in FIG. 4C,the raceway 112 includes first and second ends 112A, 112B disposed atthe first and second ends 132, 134 of the seatback carrier module 90.First and second upwardly extending portions 112C, 112D of the raceway112 extend upwardly from the first and second ends 112A, 112B of theraceway 112, respectively. At a general shoulder height position of theseatback carrier module 90, the raceway 112 includes inwardly extendingportions 112E, 112F, which further culminate at an upper transverseportion 112G. Collectively, the portions 112C, 112D, 112E, 112F, and112G of the raceway 112 disposed between the first and second ends 112A,112B of the raceway 112 define a body portion 112H of the raceway 112having an inverted U-shaped configuration. In this way, the body portion112H of the raceway 112 of the seatback carrier module 90 extends allthe way around the seatback carrier module 90 at an outer portionthereof between the first and second ends 132, 134 of the seatbackcarrier module 90. As further shown in FIG. 4C, the access aperture 130is shown disposed along the first side member 92 of the seatback carriermodule 90 and is positioned between the inner edge 106 of the cradleportion 102 and outer edge 118 of the mounting portion 104 of theseatback carrier module 90. It is contemplated that the access aperture130 may be disposed along the second side member 94 of the seatbackcarrier module 90 for a different seat configuration, such as a driver'sside seat configuration. In such a configuration, the access aperture130 would again be positioned between the inner edge 106 of the cradleportion 102 and the outer edge 118 of the mounting portion 104.

Referring now to FIG. 5A, the seatback carrier module 90 is shown from afront perspective view with an airbag assembly 150 and first and secondinflator mechanisms 142, 144 exploded away therefrom. The inflatormechanisms 142, 144 each include cylindrical body portions 146 havingupper and lower mounting stems 147, 148 which are used to couple theinflator mechanisms 142, 144 to the seatback frame 30, as furtherdescribed below. The inflator mechanisms 142, 144 may be partiallyreceived within the cradle portion 102 of the seatback carrier module 90along the lower portions 112A, 112B of the raceway 112, such that thefirst inflator mechanism 142 is positioned on or near the first sidemember 92 of the seatback carrier module 90, and the second inflatormechanism 144 is positioned on or near the opposing second side member94 of the seatback carrier module 90. It is further contemplated thatthe first and second inflator mechanisms 142, 144 are positioned outsideof the seatback carrier module 90 adjacent to the first and second loweraccess slots 136, 138 disposed on the first and second side members 92,94 of the seatback carrier module 90, respectively. In use, the firstand second inflator mechanisms 142, 144 are used to inflate the airbagassembly 150 in response to a detected condition of the seat assembly 10or the vehicle 12 in which the seat assembly 10 is contemplated to bedisposed.

As further shown in FIG. 5A, the airbag assembly 150 includes first andsecond ends 150A, 150B which further include upwardly extending portions150C, 150D, respectively. At a general shoulder height position of theairbag assembly 150, the airbag assembly 150 includes inwardly extendingportions 150E, 150F, which further culminate at an upper transverseportion 150G. Collectively, the portions 150C, 150D, 150E, 150F, and150G of the airbag assembly 150 disposed between the first and secondends 150A, 150B define an elongate body portion 150H of the airbagassembly 150, such that the airbag assembly 150 is an elongate memberhaving an inverted U-shaped configuration. In this way, the body portion150H of the airbag assembly 150 extends all the way around of theseatback carrier module 90 as received in the raceway 112 thereofbetween the first and second ends 132, 134 of the seatback carriermodule 90. It is contemplated that the airbag assembly 150 is a flexiblemember, such that the body portion 150H of the airbag assembly 150 canbe contoured to fit within the raceway 112 of the cradle portion 102 ofthe seatback carrier module 90, as further described below withreference to FIGS. 5B-5E. Thus, it is contemplated that the invertedU-shaped configuration of the airbag assembly 150 is provided by theairbag assembly 150 being stowed within the raceway 112 of the cradleportion 102 of the seatback carrier module 90, wherein the raceway 112includes a substantially rigid U-shaped configuration to receive andsupport the airbag assembly 150.

Referring now to FIGS. 5B, 5C and 5E, the airbag assembly 150 is shownreceived within the cradle portion 102 of the seatback carrier module 90at the raceway 112 thereof. With specific reference to FIGS. 5C and 5E,the portions 150C, 150D, 150E, 150F, and 150G of the body portion 150Hof the airbag assembly 150 are shown aligned with the portions 112C,112D, 112E, 112F, and 112G of the body portion 112H of the raceway 112.As further shown in FIG. 5C, the first and second ends 150A, 150B of theairbag assembly 150 are shown received in the raceway 112 at the firstand second ends 112A, 112B of the raceway 112. In this way, the airbagassembly 150 shown in the embodiment of FIGS. 5A-5E extends along anentire length of the raceway 112 between the first and second ends 112A,112B. It is contemplated that the airbag assembly 150 may be disposedpartially along the length of the raceway 112, however, the airbagassembly 150 of the present concept is provided to surround the entireseatback assembly 18 at an outer portion thereof, such that the airbagassembly 150 is an overhead airbag assembly that surrounds the arms,torso and head of a seat occupant as seated within the seat assembly 10(FIGS. 1 and 2). This surround configuration of the airbag assembly 150relative to a seat occupant is further illustrated in FIGS. 11A and 11Bdescribed below.

Referring now to FIGS. 5B-5D, the first and second inflator mechanisms142, 144 are shown received within the raceway 112 adjacent the accessslots 136, 138 respectively. With specific reference to FIG. 5D, thesecond inflator mechanism 144 is shown disposed adjacent to access slot138 of the raceway 112 of the second side member 94 of the seatbackcarrier module 90, such that the body portion 146 of the second inflatormechanism 144 is exposed or accessible through the access slot 138. Theupper and lower mounting stems 147, 148 of the second inflator mechanism144 are shown extending inwardly from the body portion 146 of the secondinflator mechanism 144 towards the centrally disposed window 100 definedby the seatback carrier module 90 through the access slot 138.Similarly, the first inflator mechanism 142 is shown disposed adjacentto access slot 136 of the raceway 112 of the first side member 92 of theseatback carrier module 90, such that the body portion 146 of the firstinflator mechanism 142 is exposed or accessible through the access slot136. The upper and lower mounting stems 147, 148 of the first inflatormechanism 142 are shown extending inwardly from the body portion 146 ofthe first inflator mechanism 142 towards the centrally disposed window100 defined by the seatback carrier module 90 through the access slot136. As noted above, the upper and lower mounting stems 147, 148 areused to couple the first and second inflator mechanisms 142, 144 to thefirst and second side members 32, 34, respectively, of the seatbackframe 30, such that the first and second inflator mechanisms 142, 144are securely mounted within the seatback assembly 18 in assembly. Asspecifically shown in FIG. 5D, the lower mounting stems 148 of the firstand second inflator mechanisms 142, 144 are disposed adjacent to thelower engagement members 126, 128, respectively, of the seatback carriermodule 90. As further shown in FIG. 5D, the first and second inflatormechanisms 142, 144 are shown disposed adjacent to the upwardlyextending portions 150C, 150D of the airbag assembly 150, respectively.It is contemplated that the first and second inflator mechanisms 142,144 are operably coupled to the airbag assembly 150 at the upwardlyextending portions 150C, 150D or at the first and second ends 150A, 150B(FIG. 5A) to provide a burst of air to the airbag assembly 150 foroutward forward deployment of the airbag assembly 150 from the cradleportion 102 of the seatback carrier module 90.

The seatback carrier module 90 is contemplated to be a modular componentwhich can be assembled with the airbag assembly 150 received in theraceway 112 of the cradle portion 102 of the seatback carrier module 90in a preassembled manner. Thus, the seatback carrier module 90 andairbag assembly 150 can be preassembled and shipped to anotherdestination for connecting the seatback carrier module 90 with theseatback frame 30. With specific reference to FIG. 5C, a plurality ofsecuring straps 155 are shown retaining the airbag assembly 150 in theraceway 112 of the seatback carrier module 90. In this way the seatbackcarrier module 90 can be transported to another location with the airbagassembly 150 securely retained within the raceway 112 of the cradleportion 102 of the seatback carrier module 90. In assembly, it iscontemplated that a front carrier module of the seat assembly 10 willretain the airbag assembly 150 within the raceway 112 as coupled to thefront portion 98 of the seatback carrier module 90, such that thesecuring straps 155 may be removed during the full assembly of the seatassembly 10.

Referring now to FIG. 6, the seatback assembly 18 is shown in anexploded view with the seatback carrier module 90 exploded away from theseatback frame 30 which is further exploded away from a back panel 160.As outlined in FIG. 6, the upper cross member 96 and the first andsecond side members 92, 94 of the seatback carrier module 90 areconfigured to be disposed outwardly adjacent to the upper frame member44 and the first and second side members 32, 34, respectively, of theseatback frame 30 when the mounting portion 104 of the seatback carriermodule 90 is mounted to the front side 30A of the seatback frame 30. Inthis way, the cradle portion 102 of the seatback carrier module 90 willbe disposed outwardly adjacent to the outer perimeter 56 of the seatbackframe 30 to substantially surround the seatback frame 30 in assembly. InFIG. 6, the inset portion 35 of the second side member 34 of theseatback frame 30 is shown having upper and lower mounting apertures147A, 148A. As noted above, the first and second side members 32, 34 ofthe seatback frame 30 are complementary members having similarconfigurations. Thus, it is contemplated that the first side member 32also includes an inset portion having upper and lower mountingapertures, as shown in FIG. 7A. It is contemplated that the insetportion 35 of the second side member 34 of the seatback frame 30 isconfigured to at least partially receive a portion of the body portion146 of the second inflator mechanism 144, such that the upper and lowermounting stems 147, 148 of the second inflator mechanism 144 can bereceived through the upper and lower mounting apertures 147A, 148A ofthe inset portion 35 of the second side member 34 of the seatback frame30 to securely mount the second inflator mechanism 144 to the seatbackframe 30. It is also contemplated that the first inflator mechanism 142is similarly mounted to the first side member 32 of the seatback frame30.

As further shown in FIG. 6, the back panel 160 is contemplated to be aclosure panel for enclosing the seatback frame 30 and seatback carriermodule 90 to a front carrier module 190 (FIGS. 8-10). The back panel 160includes a front side 160A and a rear side 160B. The back panel 160includes first and second sides 162, 164 which are interconnected by anupper portion 166 and a lower portion 168 to define a cavity 170therebetween. The cavity 170 includes a back support portion 172 and aheadrest support portion 174 which is disposed above the back supportportion 172. In assembly, the headrest support portion 54 of theseatback frame 30 is received in the headrest support portion 174 of theback panel 160. Similarly, the back support portion 52 of the seatbackframe 30 is received in the back support portion 172 of the back panel160 in assembly. The back panel 160 includes an outer perimeter 176 thatis configured to surround the outer edge 108 of the cradle portion 102of the seatback carrier module 90. The back panel 160 further includes afront edge 178 that is used to couple the back panel 160 to a frontcarrier module around the seatback frame 30. The back panel 160 furtherincludes first and second landings 182, 184 disposed near lower portionsof the first and second sides 162, 164. The first and second landings182, 184 inwardly extend from the first and second sides 162, 164,respectively, to provide a substantially horizontal surface forsupporting the seatback carrier module 90. Specifically, in assembly,the first and second landings 182, 184 are configured to support thefirst and second ends 132, 134 of the seatback carrier module 90,respectively, in an abutting relationship.

With reference to FIGS. 7A-7C, the seatback carrier module 90 is shownbeing mounted to the seatback frame 30. With specific reference to FIG.7A, the seatback carrier module 90 must pivot and orientate itselfaround the mounting bracket 62 (FIG. 6) of the seat belt retainer 60 inorder to mount to the front side 30A of the seatback frame 30. As such,the access aperture 130 positioned between the mounting portion 104 andthe cradle portion 102 of the seatback carrier module 90 must be alignedwith the mounting bracket 62 of the seat belt retainer 60 to allow themounting bracket 62 of the seatbelt retainer 60 to extend through theaccess aperture 130 of the seatback module carrier 90 for properlypositioning the mounting portion 104 of the seatback carrier module 90to the front side 30A of the seatback frame 30. Thus, the seatbackcarrier module 90 must approach the seatback frame 30 at an angle toallow for the retaining bar 66 and plate portion 64 of the seatbeltretainer 60 to pass through the access aperture 130 disposed on thefirst side member 92 of the seatback carrier module 90 in a manner asshown in FIG. 7B. As further shown in FIG. 7A, the inset portion 35 offirst side member 32 of the seatback frame 30 is shown having upper andlower mounting apertures 147A, 148A for receiving the upper and lowermounting stems 147, 148 of the first inflator mechanism 142 in assembly.

Once the seatbelt retainer 60 has passed through the access aperture 130of the seatback carrier module 90, the second side member 94 of theseatback carrier module 90 must be maneuvered around and coupled to thesecond side member 34 of the seatback frame 30 as shown in FIG. 7C.Thus, as fully mounted together, as shown in FIG. 7C, the seatback frame30 is received within the centrally disposed window 100 defined by theseatback carrier module 90. Specifically, the mounting portion 104 ofthe seatback carrier module 90 is mounted to the front side 30A of theseatback frame 30. As shown in FIG. 7C, the body portion 120 andrearwardly extending sidewall 124 of the mounting portion 104 arewrapped around the upper frame member 44 of the seatback frame 30. Asfurther shown in FIG. 7C, the lower engagement members 126, 128 arecoupled to the front side 30A of the seatback frame 30 at lower portionsof the first and second side members 32, 34 of the seatback frame 30. Inthis way, the first and second side members 92, 94 of the seatbackcarrier module 90 are coupled to the first and second side members 32,34 of the seatback frame 30. It is contemplated in FIG. 7C that theupper and lower mounting stems 147, 148 of the first and second inflatormechanisms 142, 144 are received in the upper and lower mountingapertures 147A, 148A of the respective first and second side members 32,34 of the seatback frame 30. As coupled to the seatback frame 30, theseatback carrier module 90 provides a cradle portion 102 having araceway 112 that surrounds an outer perimeter 56 (FIG. 6) of theseatback frame 30 for receiving an airbag assembly 150 therein. In thisway, the airbag assembly 150 surrounds the outer perimeter 56 of theseatback frame 30 for forward deployment around a seat occupant.

Referring now to FIG. 8, a front carrier module 190 is shown coupled tothe back panel 160 around the seatback frame 30 and the seatback carriermodule 90. A central cushion member of the front carrier module 190 hasbeen removed to reveal the cavity 170 of the back panel 160 and thefront side 160A thereof. At the zoomed in location identified aslocation 8A in FIG. 8, the seatback carrier module 90 is shown mountedto the seatback frame 30. Specifically, the body portion 120 of themounting portion 104 of the seatback carrier module 90 is mounted to thefront side 30A of the seatback frame 30. The cradle portion 102 of theseatback carrier module 90 is shown disposed outboard of the outerperimeter 56 of the seatback frame 30. The cradle portion 102 is shownhaving inner and outer edges 106, 108 with the rearwardly extending bodyportion 110 disposed therebetween in a curved manner to define theraceway 112 in which the airbag assembly 150 is disposed.

At the zoomed in location identified as location 8B in FIG. 8, theseatback carrier module 90 is shown mounted to the seatback frame 30.Specifically, the lower engagement member 126 of the mounting portion104 of the seatback carrier module 90 is mounted to the front side 30Aof the seatback frame 30 with the rearwardly extending sidewall 126Awrapped around the front side 30A of the seatback frame 30 and disposedalong the inner edge 58 of the seatback frame 30. The cradle portion 102of the seatback carrier module 90 is shown disposed outboard of theouter perimeter 56 of the seatback frame 30, and the first inflatormechanism 142 is shown disposed in the inset portion 35 of the firstside member 32 of the seatback frame 30. As further shown at the zoomedin location identified as location 8B in FIG. 8, the front edge 178 ofthe back panel 160 is operably coupled to a rear edge 192 of the frontcarrier module 190 to form a joint 194 therebetween. It is contemplatedthat the airbag assembly 150 will separate the front carrier module 190and the back panel 160 at the joint 194 to deploy in a forward directionaround a seat occupant in a manner as shown in FIGS. 11A and 11B.

Referring now to FIG. 9, the airbag assembly 150 is shown disposedwithin the raceway 112 of the seatback carrier module 90. In theembodiment shown in FIG. 9, the airbag assembly 150 includes a strap 200which outwardly extends from the body portion 150H of the airbagassembly 150 at a first end 202 of the strap 200. The strap 200 furtherincludes a second end 204 which is operably coupled to the inner edge 58of the seatback frame 30, such that the strap 200 wraps around the rearside 30B of the seatback frame 30. The strap 200 extends from theraceway 112 to the seatback frame 30 through a slot 113 disposed throughthe body portion 110 of the cradle portion 102. In FIG. 9, straps 200are shown coupled to the first and second side member 32, 34 of theseatback frame 30. It is further contemplated that the airbag assembly150 may include a plurality of straps for mounting the airbag assembly150 to the seatback frame 30. As such, it is contemplated that thestraps 200 of the plurality of straps of the of the airbag assembly 150may be evenly spaced-apart along portions of the body portion 150H ofthe airbag assembly 150 for securely mounting the airbag assembly 150 tothe seatback frame 30. Such a configuration of mounting the airbagassembly 150 to the seatback frame 30 provides for a reinforcingconfiguration against a seat occupant whom can impart a forwardlydirected force on the airbag assembly 150 after the airbag assembly 150has been deployed. The straps 200 help to redirect such forces.

Referring now to FIG. 10, the airbag assembly 150 is shown disposedwithin the raceway 112 of the seatback carrier module 90 along the sidemembers 32 and 34 of the seatback frame 30. The lower engagement members126, 128 of the mounting portion 104 of the seatback carrier module 90are shown having respective rearwardly extending sidewalls 126A, 128Awrapped around the inner edge 58 of the seatback frame 30 to securelycouple the seatback carrier module thereto.

Referring now to FIGS. 11A and 11B, a seat occupant 210 is shown seatedon the seat assembly 10. In FIGS. 11A and 11B, the airbag assembly 150is shown in the deployed position. With the airbag assembly 150 beingand overhead airbag assembly disposed around the seatback assembly 18,the airbag assembly 150 is configured to deploy outwardly along the pathas indicated by arrow 212 to surround the seat occupant 210 as shown inFIGS. 11A and 11B.

According to one aspect of the present invention, a seatback carriermodule includes first and second side portions spaced-apart from oneanother and interconnected by an upper portion. A cradle portion isdisposed along the first and second side portions and the upper portionof the seatback carrier module. The cradle portion includes inner andouter edges with a rearwardly extending body portion. A mounting portionis disposed along a portion of the inner edge of the cradle portion. Themounting portion includes inner and outer edges with a body portiondisposed therebetween. The mounting portion further includes arearwardly extending sidewall disposed along the inner edge of themounting portion. An airbag assembly is received within the cradleportion.

Embodiments of the first aspect of the invention can include any one ora combination of the following features:

-   -   the body portion of the cradle portion defines a raceway having        first and second ends with a body portion disposed therebetween;    -   the body portion of the raceway includes first and second        upwardly extending portions which respectively extend upwardly        from the first and second ends of the body portion of the        raceway along the first and second side portions;    -   the body portion of the raceway further includes an upper        transverse portion which interconnects the first and second        upwardly extending portions of the body portion of the raceway;    -   the body portion of the raceway includes an inverted U-shaped        configuration;    -   the airbag assembly is an elongate airbag assembly having first        and second ends with a body portion disposed therebetween, and        further wherein the first and second ends of the airbag assembly        are received in the first and second ends of the raceway; and    -   the body portion of the airbag assembly is substantially        received along an entirety of the body portion of the raceway.

According to another aspect of the present invention, a seatback carriermodule includes a mounting portion having inner and outer edges with abody portion disposed therebetween. The mounting portion furtherincludes a rearwardly extending sidewall disposed along the inner edgeof the mounting portion. A cradle portion is disposed along andsurrounds the outer edge of the mounting portion. The cradle portionincludes an outwardly opening raceway having first and second ends withan upwardly curved body portion disposed between the first and secondends. An airbag assembly is received within the outwardly openingraceway of the cradle portion for outward deployment therefrom.

Embodiments of the second aspect of the invention can include any one ora combination of the following features:

-   -   the airbag assembly is an elongate airbag assembly having first        and second ends with a body portion disposed therebetween;    -   the first and second ends of the airbag assembly are received in        the first and second ends of the outwardly opening raceway;    -   the body portion of the airbag assembly is substantially        received along an entirety of the body portion of the outwardly        opening raceway;    -   the outwardly opening raceway is defined between inner and outer        edges of the cradle portion and a rearwardly extending portion        interconnecting the inner and outer edges of the cradle portion;    -   inwardly opening opposed first and second access slots disposed        through the rearwardly extending portion of the outwardly        opening raceway; and    -   at least one inflator mechanism operably coupled to the airbag        assembly and disposed adjacent to one of the first access slot        and the second access slot and accessible therethrough.

According to yet another aspect of the present invention, a seatbackassembly includes a seatback frame having first and second side membersdefining a back support portion of the seatback frame. An upper framemember interconnects the first and second side members of the seatbackframe to define a headrest support portion of the seatback frame. Theupper frame member extends upwardly from the back support portion of theseatback frame. The seatback frame includes an outer perimeter disposedaround the first and second side members and the upper frame member. Aseatback carrier module is operably coupled to the seatback frame andincludes a cradle portion outwardly extending from the outer perimeterof the seatback frame. An airbag assembly is supported by the seatbackcarrier module. The airbag assembly is disposed on opposed sides of theback support portion of the seatback frame and is further disposed overthe headrest support portion of the seatback frame.

Embodiments of the third aspect of the invention can include any one ora combination of the following features:

-   -   the cradle portion includes an inner edge and an outer edge with        a rearwardly extending body portion disposed therebetween to        define a raceway;    -   the airbag assembly is received in the raceway of the seatback        carrier module around the outer perimeter of the seatback frame;    -   the seatback carrier module includes a mounting portion inwardly        disposed along a portion of the inner edge of the cradle        portion, and further wherein the mounting portion is operably        coupled to the seatback frame; and    -   the seatback carrier module includes an access aperture disposed        between the cradle portion and the mounting portion.    -   the seatback frame includes a mounting bracket outwardly        extending from one of the first and second side members, and        further wherein the mounting bracket is received through the        access aperture of the seatback carrier module when the seatback        carrier module is coupled to the seatback frame.

It is to be understood that variations and modifications can be made onthe aforementioned structure without departing from the concepts of thepresent invention, and further it is to be understood that such conceptsare intended to be covered by the following claims unless these claimsby their language expressly state otherwise.

What is claimed is:
 1. A seatback carrier module, comprising: first andsecond side portions spaced-apart from one another and interconnected byan upper portion; a cradle portion disposed along the first and secondside portions and the upper portion, the cradle portion having inner andouter edges with a rearwardly extending body portion disposedtherebetween; and an airbag assembly received within the cradle portion.2. The seatback carrier module of claim 1, wherein the body portion ofthe cradle portion defines a raceway having first and second ends with abody portion disposed therebetween.
 3. The seatback carrier module ofclaim 2, wherein the body portion of the raceway includes an invertedU-shaped configuration.
 4. The seatback carrier module of claim 3,wherein the airbag assembly is an elongate airbag assembly having firstand second ends with a body portion disposed therebetween.
 5. Theseatback carrier module of claim 4, wherein the first and second ends ofthe airbag assembly are received in the first and second ends of theraceway.
 6. The seatback carrier module of claim 4, wherein the bodyportion of the airbag assembly is substantially received along anentirety of the body portion of the raceway.
 7. The seatback carriermodule of claim 1, wherein the body portion of the cradle portion isrearwardly curved between the inner and outer edges.
 8. The seatbackcarrier module of claim 1, including: one or more reinforcement strutsdisposed along a front surface of the cradle portion, wherein the one ormore reinforcement struts span a width of the cradle portion between theinner and outer edges thereof.
 9. The seatback carrier module of claim1, including: one or more reinforcement ribs disposed along a rearsurface of the cradle portion, wherein the one or more reinforcementribs span a width of the cradle portion between the inner and outeredges thereof.
 10. A seatback carrier module, comprising; a cradleportion having an outwardly opening raceway, wherein the racewayincludes first and second ends with an upwardly curved body portiondisposed between the first and second ends of the outwardly openingraceway; and an airbag assembly received within the outwardly openingraceway of the cradle portion for outward deployment therefrom.
 11. Theseatback carrier module of claim 10, wherein the airbag assembly is anelongate airbag assembly having first and second ends with a bodyportion disposed therebetween.
 12. The seatback carrier module of claim11, wherein the first and second ends of the airbag assembly arereceived in the first and second ends of the outwardly opening raceway.13. The seatback carrier module of claim 11, wherein the body portion ofthe airbag assembly is substantially received along an entirety of thebody portion of the outwardly opening raceway.
 14. A seatback assembly,comprising: a seatback frame having first and second side membersinterconnected by an upper frame member, wherein the seatback frameincludes an outer perimeter disposed around the first and second sidemembers and the upper frame member; a seatback carrier module operablycoupled to the seatback frame, wherein the seatback carrier includes araceway outwardly disposed around a portion of the outer perimeter ofthe seatback frame; and an airbag assembly supported by the seatbackcarrier module.
 15. The seatback assembly, wherein the airbag assemblyis disposed over the upper frame member.
 16. The seatback assembly ofclaim 15, wherein the raceway includes an inner edge and an outer edgewith a rearwardly extending body portion disposed therebetween to definea forwardly opening raceway.
 17. The seatback assembly of claim 14,wherein the airbag assembly is received in the raceway of the seatbackcarrier module around the outer perimeter of the seatback frame.
 18. Theseatback assembly of claim 14, wherein the seatback carrier moduleincludes a mounting portion inwardly disposed along a portion of theinner edge of the raceway, and further wherein the mounting portion isoperably coupled to the seatback frame.
 19. The seatback assembly ofclaim 18, wherein the seatback carrier module includes an accessaperture disposed between the raceway and the mounting portion, andfurther wherein the seatback frame includes a mounting bracket outwardlyextending from one of the first and second side members, and furtherwherein the mounting bracket is received through the access aperture ofthe seatback carrier module when the seatback carrier module is coupledto the seatback frame.
 20. The seatback assembly of claim 14, including:one or more straps operably coupled between the seatback frame and theairbag assembly.